Manufacturing a crucible for containment using non-wetting materials

Abstract

A method of containing molten aluminum using non-wetting materials comprising depositing MgAl 2 O 4 , or one selected from an oxide, Al 2 O 3 , nitride, AlN, BN, carbide, and SiC, onto a crucible. An apparatus for containment of molten aluminum using non-wetting materials comprising a layer of MgAl 2 O 4 , or one selected from an oxide, Al 2 O 3 , nitride, AlN, BN, carbide, and SiC, deposited onto a crucible.

What we claim is: 
     
       1. A method of manufacturing a crucible comprising:
 masking off a crucible using a mask to confine any deposition to the rim of the crucible; 
 depositing a non-wetting material onto the crucible; and 
 rotating the crucible during deposition; 
 wherein the step of depositing the non-wetting material onto the crucible was via RF magnetron sputtering and wherein the RF magnetron sputtering was at an energy density of ˜9 W/cm 2  and a pressure of 1-10 mT and wherein the crucible was held at room temperature for an estimated non-wetting material film thickness of at least 500 mm. 
 
     
     
       2. The method of manufacturing a crucible of  claim 1  further comprising the steps of:
 removing the mask from the crucible; and 
 cleaning the crucible using solvents. 
 
     
     
       3. The method of manufacturing a crucible of  claim 1  wherein the step of rotating the crucible during deposition was at ˜10 rpm during deposition. 
     
     
       4. The method of manufacturing a crucible of  claim 1  wherein the non-wetting material is one selected from the group consisting of MgAl 2 O 4 , oxides, Al 2 O 3 , nitrides, AlN, BN, carbides, and SiC. 
     
     
       5. A method of manufacturing a crucible for containment of a molten substance using non-wetting materials comprising:
 masking off a crucible using a mask to confine any deposition to the rim of the crucible; 
 depositing a non-wetting material onto the crucible; and 
 rotating the crucible during deposition; 
 wherein the step of depositing the non-wetting material onto the crucible was via RF magnetron sputtering and wherein the RF magnetron sputtering was at an energy density of ˜9 W/cm 2  and a pressure of 1-10 mT and wherein the crucible was held at room temperature for an estimated non-wetting material film thickness of at least 500 nm; and 
 wherein the non-wetting material stops a molten substance at an edge of the non-wetting material and wherein the molten substance will not advance further. 
 
     
     
       6. The method of manufacturing a crucible for containment of a molten substance using non-wetting materials of  claim 5  wherein the non-wetting material has a surface energy that results in a contact angle of about 90° or greater when in contact with the molten substance.